Mondi is a registered trademark of Monsanto Enviro-chem for their improved ductile iron piping

system for strong sulphuric acid (>92% H2!"#$ Mondi is a special ductile iron %ith closely
controlled metallurgy and proprietary modifications for improved performance in acid service$ &t
has improved corrosion resistance to 92-99% acid' at temperatures up to ("9)* (+,,)-#$ &t is
9.% ferrite for e/cellent performance around anodically protected acid coolers$
Mondi piping systems operate at higher velocities than standard ductile and gray cast iron$
0elocities range from ($2 to +$, m1s (" to (, ft1s# for +2 to +,2 line si3es$
pools are manufactured in accordance %ith 45& standards 42($.( and 42($(.
6he Mondi system not only involves the improved metallurgy 7ut includes the entire piping
system such as8
pecially engineered flange face finish
pecially design stepped gaskets (tep 9ing -a%n :ylon
6M
gaskets#
pecial :ylon; gasket material that is free of as7estos
pecial <6-E 7ased thread sealant
-lange 7olt tightening procedure
hop hydrotesting of all piping components
6hese features result in superior piping systems that %ill provide 2, plus years of e/cellent
services8
uperior ductility eliminates the catastrophic failure and 7reakage that can occur %ith
7rittle gray cast iron$
<ipe and fittings have dura7le heavy %all construction$
Most patterns for fittings have 7een improved to eliminate chaplets$
pecial flange face finish has serrated spiral grooves %ith a pointed profile that 7ites into
the gasket for a tight seal$
4<6=s special step gasket is made of -a%n :ylon$ &t provides an e/cellent seal in the
critical sealing are at the pipe inside diameter$
Quality:
4ll Mondi cast pipe and fittings are produced in state-of-the-art foundries$ *hemical and physical
tests are performed on each foundry heat %ith material certification for tracea7ility$
4ll Mondi pipe is hydrostatically tested to .,, psi' and ultrasonic thickness tests are performed
in close increments %hen manufactured$ -langed pipe spools fa7ricated at the factory are air
tested under %ater at ., psi to ensure thread seal' pipe and fittings integrity$
Materials are su7>ected rigorous (,,% inspection for ?uality' %orkmanship' dimensions and
revie% of pertinent material certifications$ 4dditional testing includes hardness tests and
microscopic e/amination of grain structure$
Corrosion :
Measured corrosion rates from many years of actual plant operation are the true measure of
M!5@& performance$ 6he initial corrosion of M!5@& is higher as the tough sulfate film is formed
on the surface$ 4fter formation' this sulfate film remains to protect the surface and corrosion rate
is greatly reduced$ 6he resulting lo% corrosion rate provides piping system relia7ility' long service
life and e/cellent performance$
ometime during the operation of an acid plant' the acid concentration in the drying or a7sor7ing
systems %ill e/perience a %eaker acid e/cursion due to process upset or e?uipment malfunction$
Aeaker acid e/cursions 7elo% 9B% %ill accelerate corrosion to austenitic stainless steel piping
and decease its service life$ Many plants have reported that their M!5@& piping systems %ith 9+-
99% have operated through %eaker acid e/cursions$ 6hese plants also reported that the M!5@&
piping did not sho% significant corrosion after the e/cursions$ M!5@& piping is very forgiving and
provides relia7le system performance$
Ma/imum spool lengths for +2 (C,mm# through B2 ((.,mm# si3e is (9$. feet (.9""mm#$ C2
(2,,mm# through +,2 (D.,mm# si3es have a ma/imum length of (D$. feet (.++"mm#$ -langes
have 45& (2. psi 7olt patterns or other standard patterns$
<ipe is cut to the re?uired length and threaded to e/acting tolerances to match each flange thread
and taper$ -langes are tightened to a specific tor?ue for leak-free pipe-flange thread seal$ -lange
centerlines and 7olt holes are aligned to proper position in our custom machine$ pools %ith
special flange rotation are aligned in this machine %hich eliminates errors$
-lange faces and end of pipe are machined flat and perpendicular to the pipe 7arrel %ith a special
phonographic finish$ -lange faces are protected %ith rust preventative and flange covers if
re?uired$
Fittings:
Mondi fittings are cast in special patterns %ith heavy %all thickness for large corrosion allo%ance
needed in the acid industry$ 6hese patterns have thicker %all than 2., psi ductile iron patterns$
ee %all thickness 7y si3e for our pipe and fittings$ -or e/ample - a ("2 9,) Mondi el7o% has a
%all thickness of ,$C22 and %eight of ++, pounds versus a %all thickness of ,$BB2 for 2., psi
ductile iron and %eight of 29, pounds used in the %ater industry$
*enter to face dimensions meet 45&14AA4 *((,142($(, standards$ 6he inside diameter of the
fittings matches the inside diameter of the pipe$ -langes have 45& (2. psi 7olt drilling or other
7olt drilling if re?uired$ Eossed fittings and other special fittings are availa7le$
<atterns for fittings are designed to virtually eliminate all chaplets$ Ahen a chaplet must 7e used'
it is made of Mondi %ith a special finned design %hich fuses in to the fitting$ 4<6 fittings have
7oth Mondi metallurgy and heavy %all thickness for superior performance$
-lange faces have the special phonographic finish %hich 7its into the gasket for a proper seal$
-langes faces are protected %ith rust preventive and flange covers if re?uired$
Mondi Bossed Fittings
Eossed M!5@& fittings are used for flanged connections of8
o thermo%ells
o pressure sensors
o drain lines
o vent lines
o sample lines
o side streams
Eosses are added to the outside %all of the fitting and do not reduce the %all thickness or service
life of the fitting$
Fsing a 7oss %ill make the fitting multi-purpose and can simplify a piping system to reduce costs$
Eosses are typically used on el7o%s and tees and can 7e placed at different locations$ 6he
diameter of the 7oss matches the outside diameter of the connecting flange$ 6he face of the 7oss
is drilled and tapped for stud 7olts and machined for a good gasket surface$ Eosses are used for
(122 to (22 si3e flanged connections
ee the information for the 7oss location and si3es availa7le$ *ontact Eay <ort 0alve G -itting for
7oss locations on other types of fittings if re?uired$
Mondi Flanged Elbows
Mondi Flanged Reducer and
Reducing Fittings
Mondi Flanged Tees And Crosses
Mondi Spacers
pacers assist in installation of the piping system$ Ae recommend that a spacer 7e used in each
hori3ontal and vertical run of piping to ad>ust for dimensional differences$ pacers are availa7le
as filler flanges and ring spacers$ pacers can 7e machined in the field during system fit-up$ this
is important for e/isting piping systems %here dimensions may have changed due to settling of
foundations over the years$
-iller flanges are full face %ith drilled 7olt holes and spiral groove phonographic finish on 7oth
sides for a good gasket surface$ 6hey match the pipe inside diameter and flange outside
diameter$ 6hey are availa7le in si3es +2 through +,2 and thickness as re?uired for system$ Ae
maintain a stock of (122' (2' 22 and +2 thick filler flanges in the different pipe si3es$
@uring field fit-up' tapered filler flanges can 7e used if mating flanges are not parallel$
9ing spacers match the pipe inside diameter and fit inside the flange 7olt circle$ 6hey are
availa7le in +2 through +,2 si3es in specific thicknesses or in a standard (22 length$ 6he standard
(22 length can 7e cut to the re?uired thickness and machined %ith a gasket surface$
Step Ri ng Fawn Gyl onTM Gaskets For Mondi Fl anges
6his gasket consists of a (1(B2 thick standard ring section plus a (1(B2 thick inner ring section$
Eoth sections are 7onded together$ 6he standard ring section is for locating and centering %ithin
the 7olt circle$ 6he inner ring section is for sealing$ 6otal thickness at the inside diameter is (1C2
(+mm# in the critical sealing area$
6here is a limit to 7olt loading for each si3e flange$ -or the tep 9ing :asket' compression is
concentrated over the smaller area of the inner ring' allo%ing the grooves in the flange face to
7ite into the gasket$ 6his provides a tight seal %ith proper tor?uing of the 7olts$ 6his gasket %orks
on the same principle as a raised face flange$ 6he tep 9ing :asket=s superior seal prevents acid
migration from inside the pipe and corrosion of the flange face %hich shortens the life of piping
systems$